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R. Craig McClungSouthwest Research Institute®
An Executive Update on theTurbine Rotor Material Design (TRMD)
Program
6th Annual FAA/Air Force/NASA/Navy Workshop on the Application of Probabilistic Methods to Gas Turbine Engines
March 18-20, 2003
Outline
Industry background and perspectiveIntroduction to the TRMD programOverview of major tasks
Recent accomplishmentsFuture work
Introduction to DARWIN™ presentations
Background
Hard Alpha anomalies in titanium engine disks
Very rareCan cause failureNot addressed by safe life methods
Enhanced life management process
Requested by FAADeveloped by engine industryProbabilistic damage toleranceSupplements safe life approach
R. Craig McClungSouthwest Research Institute®
Aerospace Industries Association
Rotor Integrity Sub-Committee
A Summary for 2003 Probabilistic Workshop
March 18, 2003
Post Sioux City - Industry moves to incorporate Damage Tolerance
Safe Life Estimate
RISC developed an industry-wide framework for Damage Tolerance … and added this element to the
existing Life Management Process
AIA Rotor Integrity Sub-CommitteeCharter
• Address Industry Policy on Rotor Safety
• Assist FAA in implementing Ti Report
• Ti first, other materials later
GE Aircraft EnginesHamilton SundstrandHoneywellMTUPratt & Whitney
Pratt & Whitney CanadaRolls RoyceRolls Royce AllisonSNECMAFAA
Enhanced Life Management
Process
Analysis Methods &Matls Data
Damage
Tolerance
Devt. & Validation
Tests
New Element Added
Service Life & Product Assurance
Enhanced Life Management
Process
Materials
Safelife
Testing
AssuranceDT
RISC Vision - Comprehensive DT Assessment
Damage Tolerance Advisory Circular
Inherent Flaws(Melt related, etc)
Titanium Hard Alpha
Ni/Powder Metals
Analytical Method:
Probabilistic FMRisk Calc <DTR
Induced Flaws
Manufacturing Maintenance/ Service
•Retain Deterministic FM as fallback
Analytical Method:
Probabilistic FMRisk Calc <DTR
Current RISC Focus
•Analysis Tool calibrated by Test Case
•Criteria Calibrated by Experience
RISC ScheduleSioux City 7/19/89 Pensacola 7/6/96 AC33.14
1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 20011989 1990 2002 2003
Draft Advisory Material to FAA 11/96
InherentAnomalies
InducedAnomalies
Ti
Ti
Ni
Ni
RISC Kickoff 10/91 Damage ToleranceFramework for all Future Work
FAA/SMPC Data GatheringOEM Data Gathering Started
Draft Advisory MaterialAvailable by 4Q2003
TRMD Goals
TRMD Program has two major goalsDevelopment of a practical software tool that implements the new probabilistic damage tolerance methodologyDevelopment of supplementary modeling and experimental characterization of material and anomaly behavior
Both goals support the implementation of FAA Advisory Circular 33.14
TRMD Team Leaders
Federal Aviation AdministrationBruce Fenton and Joe Wilson, Technical CenterTim Mouzakis, New England Regional Center
TRMD Subcontractors and Steering CommitteeDarryl Lehmann, Pratt & WhitneyJon Tschopp, General ElectricAhsan Jameel, HoneywellJon Dubke, Rolls-Royce Corp.
AIA Rotor Integrity Subcommittee (RISC)Southwest Research Institute
Gerry Leverant, original Program ManagerCraig McClung, current Program Manager
Major TRMD Phase II Contributors
General ElectricJon TschoppT. C. ChangShesh SrivatsaAndy WoodfieldGary MihlbachlerJon Bartos
HoneywellAhsan JameelYancy GillSandeep MujuMike Gorelik
Pratt & WhitneyDarryl LehmannMas Hongoh
Rolls-Royce Corp.Jon DubkeGeoff Ward
Southwest Research InstituteGerry LeverantCraig McClungMike EnrightLuc HuyseYi-Der LeeGraham ChellPete McKeighanKwai ChanPete LazChris Waldhart
Harry Millwater (UT-San Antonio)Simeon Fitch (Mustard Seed Software)
Major TRMD Tasks
Hard Alpha anomaly distribution updateValidation of forging deformation modelCrack nucleation/growth data and modelingDARWIN™ software development/validationTechnology transfer
Example HA Distributions
Post 1995 Triple Melt/Cold Hearth + VAR
1.00E-02
1.00E-01
1.00E+00
1.00E+01
1.00E+02
1.00E+02 1.00E+03 1.00E+04DEFECT INSPECTION AREA (sq mils)
EXC
EED
ENC
E(p
er m
illio
n po
unds
)
MZ(5-10in Billet)/#1 FBH
MZ(5-10in Billet)/#3 FBH
MZ (12-13in Billet)/#1 FBH
#2/#1 FBH
#2/#2 FBH
#3/#1 FBH
#3/#2 FBH
#3/#3 FBH
HA Anomaly Distribution Derivation Process
Ingot
Hard Alpha Area
#
BarDeformation
Hard Alpha Area
#
Bar Inspection #2 FBH
POD
Hard Alpha Area
#
BilletDeformation
Hard Alpha Area
#
Billet Inspection #3 FBH
POD
Hard Alpha Area
#
Forging
Hard Alpha Area
#
Forging Inspection#3 FBH
POD
Hard Alpha Area
#
Finished Part
Hard Alpha Area
#
JETQC Data
Hard Alpha Area
#
Hard AlphaFound
Hard AlphaRemaining
Hard Alpha Area
Field Calibration
POE
Hard Alpha Area
Final Distribution
POE
Hard Alpha Area
Distribution Shape
Initial Guess
#
0 103 5
1 9A
2 4 6 7 8
HA Distribution Update
Current distributions derived by RISC from complex analysis process calibrated to field experience
Details provided in 1997 SDM conference paper
TRMD/RISC effort underway to derive improved HA distributions based on new data/technology, including…
Vacuum fatigue crack growth rate behaviorImprovements in melt practice/material cleanlinessNew Probability-of-Detection curves for NDE inspectionsNew model for forging/anomaly deformationCharacterization of HA anomaly (core vs. diffusion zone)
New distributions will be calibrated to field experience
Similar work planned for anomalies in cast/wrought Ni
Deformation Modeling
Microcode to predict shape/orientation change for HA anomalies during forging has been developed and integrated into DEFORM softwareForging experiments with seeded billets conducted to validate the code
Billet to pancakeBillet to pancake to backflowBillet to pancake to final sonic shape (spin pit tests)
NDE and post-test metallography conducted to characterize defect morphology and inspectabilityRegression equations derived to predict HA deformation from fundamental forging variables
Recent Material Behavior Tasks
Vacuum fatigue crack growth dataPreviously generated on Ti-6-4, Ti-6-2-4-2, Ti-17Recently generated on WaspaloyTesting underway or planned for IN-718, P/M U720
Fatigue testing of coupons from seeded forgingsCompare test life with analytical predictionsSimilar tests planned for natural anomalies in Ni
Experimental study of Ti-17 with high oxygenDwell fatigue life debit found earlier for Ti-6242 + OSmaller (probably negligible) effect found for Ti-17 + O
Literature review of surface residual stress effectsFocus on stress relaxation, influence on FCG rates
DARWIN™ Overview
Probabilistic Fracture Mechanics
Probability of DetectionAnomaly Distribution
Finite Element Stress Analysis
Material Crack Growth Data
NDE Inspection Schedule
Pf vs. Cycles
Risk Contribution Factors
DARWIN™ Development
Version 4.0 (Alpha – Jan 2002, Production – Aug 2002)Initial version for surface damageFracture analysis for cracks at holes
Version 4.1 (Alpha – Nov 2002)Automated report generationImportance sampling confidence bounds
Version 4.2 (Alpha – Feb 2003)PC and Linux versionsExecute analysis code directly from GUI
Version 5.0 (Alpha – April 2003)Initial 3D GUIMission mixing
Version 6.0 (2004-2005)Multiple defectsAdvanced 3D capabilities
TRMD DARWIN™ Presentations
Mike Enright (SwRI)Summary of New DARWIN™ Capabilities for Surface Damage Tolerance Assessment and Related Enhancements
Luc Huyse (SwRI)Recent Probabilistic Computational Efficiency Enhancements in DARWIN™
Ahsan Jameel (Honeywell)Application of DARWIN™ to Evaluate Risk of Fracture Due to Material Anomalies in Gas Turbine Engines
Technology Transfer
DARWIN™ distribution4 TRMD partner companies evaluate extensively4 engine companies have licensed DARWIN to dateRoyalty-free license available to US Govt agencies
DARWIN useFAA certification analyses on 10+ componentsAbout 20 OEM engineers trained in use of DARWIN
DARWIN trainingNew on-line help systemAvailable for licenseesWorkshop planned at end of TRMD Phase 2 program
DARWIN and TRMD informationAvailable on DARWIN web site
Web Site: www.darwin.swri.org
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